Ultrasonic welding of annular components

Abstract

A method of making an annular component includes forming sheet feedstock into an annular shape disposed about a central axis; and bonding one portion of the feedstock to another portion of the feedstock using ultrasonic welding, so as to fix the annular shape.

What is claimed is: 
     
       1. A method of making an annular component, comprising:
 forming sheet feedstock into an annular shape disposed about acentral axis; 
 bonding one portion of the sheet feedstock to another portion of the sheet feedstock using ultrasonic welding, so as to fix the annular shape; 
 repeating the steps of forming and bonding sheet feedstock to create a plurality of concentric layers; and 
 forming bonds between the plurality of concentric layers using ultrasonic welding, 
 wherein the plurality of concentric layers includes a first group of layers which are continuous, and a second group of layers which are discontinuous having solid portions defining internal open voids, so as to define at least one raised feature on an inner or outer surface of the annular component. 
 
     
     
       2. The method of  claim 1  further comprising machining the component to define one or more features. 
     
     
       3. The method of  claim 1  wherein a first of the plurality of concentric layers comprises a first metal alloy, and wherein a second of plurality of concentric layers comprises a second metal alloy different from the first metal alloy. 
     
     
       4. A method of making an annular component, comprising:
 forming sheet feedstock into an annular shape disposed about a central axis; 
 bonding one portion of the sheet feedstock to another portion of the sheet feedstock using ultrasonic welding, so as to fix the annular shape; 
 repeating the steps of forming and bonding sheet feedstock to create a plurality of concentric layers; and 
 forming bonds between the plurality of concentric layers using ultrasonic welding, 
 wherein the plurality of concentric layers includes a first group of layers which are continuous, a second group of layers of the plurality of concentric layers which define open spaces therebetween, and a third group of layers of the plurality of concentric layers which are continuous, so as to define at least one interior space which is bounded by the first, second, and third groups of layers, 
 wherein the second group of layers is positioned between the first group of layers and the third group of layers. 
 
     
     
       5. The method of  claim 4  further comprising disposing a nonmetallic filler into the interior space. 
     
     
       6. The method of  claim 1  wherein the annular shape formed during the forming step has free ends, and ultrasonic welding is used to bond the free ends together, forming a butt joint or a lap joint therebetween. 
     
     
       7. The method of  claim 1  wherein the forming step is performed by feeding the sheet feedstock against one or more forming elements, the one or more forming elements being positioned about the central axis. 
     
     
       8. The method of  claim 7  wherein the forming elements include a plurality of rollers. 
     
     
       9. The method of  claim 7  wherein the ultrasonic welding is carried out while the feedstock is surrounded by the forming elements. 
     
     
       10. The method of  claim 1  wherein the annular component has a generally cylindrical shape. 
     
     
       11. A method of making an annular turbine engine component, comprising:
 feeding sheet metal feedstock into a forming apparatus having at least one forming element; 
 forming sheet metal feedstock into an annular shape using the at least one forming element to deflect the sheet metal feedstock, causing it to bend and form into a curve; 
 bonding one portion of the sheet metal feedstock to another portion of the sheet metal feedstock using ultrasonic welding; 
 repeating the steps of forming and bonding sheet metal feedstock to create a plurality of concentric layers; and 
 forming bonds between the plurality of concentric layers using ultrasonic welding, 
 wherein the plurality of concentric layers includes a first group of layers which are continuous, and a second group of layers which are discontinuous having solid portions defining internal open voids, so as to define at least one raised feature on an inner or outer surface of the annular component, 
 wherein the forming bonds between the plurality of concentric layers is performed at intervals around the annular shape. 
 
     
     
       12. The method of  claim 11  wherein a first of the plurality of concentric layers comprises a first metal alloy, and a second of the plurality of concentric layers comprises a second metal alloy different from the first metal alloy. 
     
     
       13. The method of  claim 11 :
 wherein the second group of layers define open spaces therebetween, the method further comprising: 
 forming the sheet metal feedstock into a third group of layers which are continuous, so as to define at least one interior space bounded by the first, second, and third groups of layers.